Manufacturing of cast bar (charged) stocks of heat-resistant nickel alloys for the 4th and 5th generation engines
A specialized scientific and production complex was created for development of pilot and commercial production technologies of nanostructured heat-resistant nickel alloys with improved combination of mechanical and operational properties for advanced aviation equipment. Productivity of the complex is 200 tons / year.
A new generation of cast super heat-resistant nickel alloys was created at FSUE "VIAM". A new generation of super heat-resistant nickel alloys ZhS36-VI, VZhM1-VI, VZhM5-VI and intermetallic alloys VKNA-1V-VI, VKNA-4U-VI, VKNA-25-VI etc. was created at VIAM. An essential increase of properties and operational characteristics of these alloys was accomplished by the obtaining nanostructured state in them under certain production conditions.
An effective technology of metal refining from impurities in vacuum provides reduced impurity content in the alloys of a new generation for single-crystal castings. Compared to alloys produced at JSC "CMK", JSC "Mechel" and JSC "VILS" the impurity content was reduced as follow: for oxygen and nitrogen 2-2.5 times, for sulphur 2-3 times. It provides to increase the mechanical properties of the alloys, their lifetime and yield as for single-crystal structure of castings.
A resource-saving technology for the remelting of wastes in vacuum allows production of charged stocks from 100% of casting waste, which in chemical composition, purity and properties fully satisfy the requirements of effective supply Specs. The produced alloys do not inferior to the alloys, made of raw charged materials, which are supplied to the engine plants from the metallurgical complexes. The alloys cost is appreciably lower: for alloys with rhenium (ZhS32) – by 40-50%, for alloys without rhenium (ZhS6U) - by 20-30%.
Manufacture of cut-to-length charged stocks has been created on the base of up-to-date melting equipment - vacuum induction furnace VIM-50 of the last generation, which was made by ALD company (Germany). The furnace is equipped with a 350 kg crucible and all functional assemblies and systems that provide high quality of melt.
Developed technology is currently used to supply ZhS6U-VI, VZhL12U-VI, ZhS26-VI, ZhS26UVI, ZhS32-VI, ZhS36-VI, VZhM1VI, VZhM4-VI, VZhM5-VI, VKNA1V-VI, VKNA-4U-VI , VKNA-25-VI alloys to the following enterprises: JSC "UMPO", JSC "Perm Engine Company", JSC "Aviadvigatel", JSC “NPO Saturn", JSC " Chernyshev MME”, FSUE “MMPP “Salut”, etc.